MACHINE DESIGN AND CAD-II

KEY POINTS (Springs, Clutches and Brakes, Bearings)

• All the stated assumptions and short notes are in accordance with class lectures.
• In case of any confusion, refer to ONLINE LECTURES as there is a probability of errors
(Logical and Typo).

Helical Compression
Static Loading Case
Spring Index C=8
Assumptions Set Spring
Square and Ground ends
Dynamic Loading Case
Spring Index C=8
Set Spring
Square and Ground ends
Peened wire

Use Ks for static loading case.

Use Kw for dynamic loading case.
In estimating wire diameter, even the value is 5.00001,
select the larger one.
In, determining relation of Sys and Sut for static loading,
use “AFTER SET” from table for static loading case
Wire Diameter Estimation and “BEFORE SET” in case of dynamic loading.
Take average value of S ys
If factor of safety is not given, assume it to be 1.3 for
wire diameter estimation.

Note: Use calculator equation solving technique to

save time.

The material is selected:

• On the basis of temperature.
• On the condition of loading (static or dynamic)
• The cost of the material should always be
Material Selection considered.
• If after the wire diameter estimation, desired
diameter is not available, move to next material.
NOTE: A228 material could be used for dynamic
loading case, but cost has to be considered.
 For calculating stresses, use Ks for
Use of Use of K s , K w
 min and  m while Kw for a

While calculating the natural frequency,

use value of “g” as 9800 ms-2
Frequency
NOTE: Remember to use same units
fn
in calculation of
ff

Always round Na to nearest quarter.

Na Calculation
(Simply round to nearest)

Helical Extension
Spring Index If not given assume
C = 10,C1 = 10,C2 = 6
Assumptions Unset Spring
Standard Hooks
Unpenned
All assumptions are same as stated earlier

Wire Diameter Estimation Multiply factor of safety with 1.3 for wire
diameter estimation. In case of 1.5, multiply
it with 1.3.
To calculate bending endurance limit,
Bending Endurance Limit 3
Use, Se = Ses
2
The maximum deflection is calculated using:
Fmax − Finitial
y max =
Maximum Deflection y work
NOTE: Here Finitial is the value calculated
from  i
The units of given equations are in psi. For SI
 i Units units, use conversion factor given in formula
sheets
 Helical Torsion
C=9
Un-peened
Assumptions
2” long straight ends
Loads are applied to close the ends
In, determining relation of Sys and Sut ,
Relation between Sys and Sut
use favourable residual stresses.

Use factor of safety 1.3 for wire diameter

Factor of Safety
estimation if not given

The value should be calculated from

Bending Endurance Limit
formula given in sheet.
Always round Na and Ne to nearest
Na and Ne Calculation quarter.
(Simply round to nearest)
Note: The wire diameter estimation rules stay same for all three springs

Question Answers Related to Spring (Online Lecture)

Calculating Life Cycles If infinite life is not given;
Use table 13.7
For any value less than 105, use 105
If values are in-between the values in
tale, use linear interpolation for
calculation
A227 → A229 → A228 → A232

The general pattern of material

selection NOTE: Only these materials are
available for wire diameter
selection.
 CLUCTHES
If not given, use uniform wear model of
Assumption of Model
clutches as it is more conservative.

If not given, assume dry clutch.

Clutch Type and Material If not given, assume moulded material as it
has the highest pressure and lowest
coefficient of friction.

Remember to use the actual value of

Calculation of inner and outside radius of
ri for ro calculation and then round to
lining
whatever provided

If service factor is given, make sure to

Service Factor “USE” it where required.
Example 15.1 for reference.

Dry and Wet Clutches Carefully read the dry and wet clutches
cases.

BRAKES

Short Shoe and Long Shoe 2  45(Short Shoe)

2  45(Long Shoe)

Friction Force Friction Force is always in direction of

rotation

Actuating Force It is same for upper and lower shoe in case

of double shoe brakes.

Maximum pressure is different for upper

Maximum Pressure and lower shoe in case of double shoe
brakes.

NOTES:
• Solve integrations directly in calculator to keep yourself safe from mess.
• Make sure to put your calculator in RADIAN MODE while evaluating integrals.
• Also, make sure to revert the MODE back to normal, when done.
• The formula sheet is still need to be updated. However, as discussed consider the
integration formulas (unevaluated) in the slides.
Design of Bearings
Good Luck!
May this journey be smooth for everyone.!